Stainless steel overcoat for sputtered films

ABSTRACT

A method is disclosed for improving the stability and durability of sputtered metal films such as silver and copper by means of depositing a protective overcoat of a metal such as stainless steel on the exposed surface of the film.

This application is a division of U.S. Ser. No. 530,570 filed Sept. 9,1983, now U.S. Pat. No. 4,594,137.

BACKGROUND OF THE INVENTION

The present invention relates generally to the art of sputteringtransparent metallic films for solar energy control, and moreparticularly to the art of controlling the color and durability ofsputtered films.

Transparent films of metals such as silver, copper, nickel and cobaltare readily produced by electroless deposition methods. U.S. Pat. No.3,457,138 to Miller discloses an electroless (wet chemical) method forproducing transparent copper films over a thin transparent silver filmon glass. Similarly produced wet chemical silver/copper films on glasshave achieved commercial success as architectural products for solarenergy control. The coating effectively reflects solar heat energy whilepresenting an aesthetically appealling low reflectance pinkish coloredsurface to the observer.

However, advances in coating technology provide alternative processesfor producing transparent metallic films for solar energy control, suchas chemical vapor deposition, vacuum evaporation deposition, and cathodesputtering. Cathode sputtering is particularly desirable for producingmetallic films in a method that is fast and efficient on a large scale.U.S. Pat. No. 4,166,018 to Chapin discloses a particularly usefulsputtering process and apparatus which employ a magnetic field toimprove cathode sputtering conditions. A sputtering apparatus isdescribed in which a magnetic field is formed adjacent a planarsputtering surface. The field comprises arching lines of flux over aclosed loop erosion region of the cathode surface.

In attempting to reproduce the properties of a wet chemical two-layersilver/copper film on glass by cathode sputtering, using known cathodesputtering techniques to produce two-layer silver/copper films atvarious thicknesses and thickness ratios, the desirable low reflectancepinkish colored appearance of the wet chemical two-layer silver/copperfilm is not obtained. Rather, typical sputtering conditions result intwo-layer silver/copper films that range in appearance from highlyreflective bright silver to highly reflective bright copper depending onthe silver/copper ratio and the orientation of the sample.

U.S. Pat. No. 4,462,884 to discloses a method for producing transparenttwo-layer silver/copper films having a low reflectance pinkish coloredappearance by cathode sputtering. The method disclosed therein requiresthe desposition of a first layer of silver in a discontinuousagglomerated state. The deposition of a continuous copper film over thediscontinuous agglomerated silver film produces the desired lowreflectance pinkish colored appearance characteristic of the wetchemical product. The deposition of silver in a discontinuousagglomerated state by cathode sputtering requires conditions which allowthe silver arriving at the substrate surface sufficient time toagglomerate. This can be accomplished by either slowing the arrival rateof silver or increasing its mobility at the substrate surface. Slowingthe arrival rate of the sputtered silver may be achieved by eitherlowering the power applied to the sputtering cathode or by increasingthe gas pressure in the vacuum chamber in which the sputtering processis being performed. Increasing the mobility of the silver may beachieved by raising the temperature or decreasing the surface energy ofthe substrate.

Unfortunately, the discontinuous silver layer applied by cathodesputtering as described above does not have as good adhesion to glass asis desired for a commercial window unit. Moreover, the degree ofagglomeration of the silver is difficult to control. The deposition ofthe silver layer is affected by the condition of the glass surface andthe method used to clean it. The color and adhesion of a dual layercoating of silver and copper are particularly difficult to optimize ifthe glass substrate has been in storage and has stain or incipient stainon the surface to be coated.

U.S. Pat. No. 4,512,863 to provides a method for achieving improvedadhesion and color control of a sputtered film of a metal such as silveror copper by means of a primer layer of a metal such as stainless steel.The sputtering of a stainless steel primer layer is particularly usefulin the production of a desirable silver/copper two-layer sputtered filmon glass. The stainless steel primer layer may be sputtered onto asubstrate surface to a thickness on the order of an atomic layer toprovide a suitable surface for the sputtering of more sensitive metalsuch as silver. Thicker primer layers are also disclosed, limited onlyby the desired final transmittance of the coated article. Two-layersilver/copper films are preferably stabilized by treatment withpassivating agents.

SUMMARY OF THE INVENTION

The present invention provides a method for achieving improved stabilityand durability of a sputtered film of a metal such as silver or copperby means of an overcoat of a metal such as stainless steel. Thesputtering of a stainless steel protective overcoat is particularlyuseful in the production of a desirable silver/copper two-layersputtered film on glass. The stainless steel overcoat may be sputteredonto the metal film to a thickness of at least about 20 Angstroms.Thicker overcoats are also useful, limited only by the desired finaltransmittance of the coated article.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Nonmetallic substrates, preferably transparent substrates such as glass,are coated with various metal and metal oxide films by cathodesputtering. The stability and durability of some metallic films, notablysilver and copper, are not as good as desired for commercial product.

In accordance with the present invention, the stability and durabilityproblems of the prior art are solved by means of an overcoat of adurable, stable metal, such as stainless steel, chromium or titanium,which forms a dense oxide surface. Preferably, a stainless steel cathodeis installed in a sputtering chamber. In a particularly preferredembodiment of the present invention, the stainless steel overcoat isapplied in conjunction with a stainless steel primer layer as disclosedin U.S. Pat. No. 4,512,863 to, the disclosure of which is incorporatedherein by reference. A clean, transparent substrate is preferably coatedwith a very thin primer layer of stainless steel prior to the depositionof other compositions such as silver and/or copper. A stainless steelovercoat is then sputtered over the silver and/or copper film to providestability and durability to the exposed surface of the film. A thinlayer of stainless steel, about 20 Angstroms thick, is sufficient toprovide the desired stability and durability. Thicker overcoats are alsouseful, limited in thickness only by the desired transmittance of thefinal coated article.

In a particularly preferred embodiment, glass substrates to be coatedwith a two-layer silver/copper film by cathode sputtering are firstcoated with a stainless steel primer layer. The glass substrates arepreferably first washed in a conventional washing operation to removeany accumulated dirt and debris. The glass may be of any composition,but soda-lime-silica float glass is preferred. Typical float glasssubstrates have a transmittance of about 90 percent in the visiblewavelength range. A clean glass substrate is placed in a sputteringchamber equipped with a stainless steel cathode. Sputtering is carriedout to form a very thin primer layer of stainless steel on the glasssurface. A silver layer is then sputtered onto the primer layer, and acopper layer sputtered over the silver layer. Finally, a stainless steelovercoat is sputtered over the copper. The thickness of the stainlesssteel overcoat may be as little as about 20 Angstroms, which decreasesthe transmittance by only about 3 percent. Such a stainless steelovercoat is sufficient to produce the desired stability and durabilityof the underlying sputtered films. Thicker overcoats, on the order of 30to 40 Angstroms, are generally preferred.

In a most preferred embodiment, wherein a two-layer film of silver andcopper is to be sputtered, it is noted that a discontinuous silver filmis not produced at useful thicknesses when silver is sputtered onto thestainless steel primer layer. As a result of the formation of acontinuous silver layer, the resultant coated article may have a morehighly reflective appearance and a more silvery or coppery color than isdesired. In accordance with the present invention, a desired pinkishcolored silver/copper coating can be formed by increasing the thicknessof the stainless steel primer layer, typically to about 20 to 25Angstroms. If the thicker primer layer produces a lower reflectance thanis desired, the reflectance can be raised by increasing the amount ofsilver relative to the amount of copper in the overlying two-layer film.Since the stainless steel overcoat further reduces the reflectance andtransmittance, the amount of silver may be further increased relative tothe amount of copper to achieve the desired appearance.

While the present invention is described in detail with regard to astainless steel primer layer on glass, an overlying silver/coppercoating deposited by cathode sputtering, and a stainless steel overcoat,various other embodiments are included within the scope of theinvention. For example, other metals which form a dense oxide surfaceare suitable protective overcoats, such as titanium, chromium, vanadium,aluminum, tin, tantalum and nickel alloys such as Inconel. Theunderlying sputtered metal may include other sensitive metals such asgold, platinum and palladium. Nonmetallic substrates other than glassmay be coated, and need not be transparent. The present invention willbe further understood from the descriptions of specific examples whichfollow.

EXAMPLES

Clear float glass sheets measuring 3 by 2 feet (91×61 centimeters) and 6millimeters thick are washed in a conventional washer. The transmissionof the clear glass measured at 550 nanometers is about 90 percent. Cleanglass sheets are coated using an in-line coating facility available fromAirco-Temescal. The coater is a semi-continuous architectural coatingfacility capable of coating glass sizes up to 7 by 12 feet (2.1 by 3.7meters) on a conveyor while employing up to nine stationary cathodeswhich are 13 by 106 inches (0.3 by 2.7 meters). Adjacent the planarsputtering surfaces is created a magnetic field comprising curved linesof magnetic flux which form a closed loop erosion region on thesputtering surface. This erosion region has a slightly irregular "ovalracetrack" shape.

Stainless steel, silver and copper cathodes are installed in the coaterin sequence. Each cathode is powered by a standard 120 kilowatt powersupply operating under power control at various percentages of the ratedpower. The speed of the conveyor and number of cathodes may be varied toobtain the desired film thickness. The atmosphere in the sputteringchamber is argon at a pressure of 3 millitorr. In this example, the linespeed is about 80 inches (about 2 meters) per minute for a single passunder stainless steel, silver and copper cathodes in sequence. Atransmission photometer which reads luminous transmission is installedon-line to monitor the transmission of the film after each stage ofcoating.

A glass substrate is conveyed under the stainless steel cathode, whichcomprises 19 percent chromium, 9 percent nickel, no more than 0.08percent carbon and the balance iron, at an applied voltage of 360 volts.A stainless steel primer layer is sputtered onto the glass surface,decreasing the transmittance from about 90 percent to about 77 percent,corresponding to a stainless steel primer layer thickness of about 21Angstroms. The stainless steel primer coated glass is then conveyedunder the silver cathode. A continuous silver layer is sputtered, at anapplied voltage of 325 volts, over the stainless steel primer layer,decreasing the transmittance of the coated glass to about 63 percent,corresponding to a silver layer thickness of about 27 Angstroms. Thesilver coated, stainless steel primed glass is conveyed under the coppercathode, at an applied voltage of 424 volts, sputtering a layer ofcopper over the silver layer, decreasing the transmittance to about 16percent, corresponding to a copper layer thickness of about 257Angstroms. Finally, the stainless steel overcoat is sputtered at anapplied voltage of 389 volts, decreasing the transmittance to 12percent, corresponding to a stainless steel overcoat thickness of about34 Angstroms.

Although thinner or thicker stainless steel layers are effective toimprove the adhesion, stability and durability of the intermediatesputtered films, the stainless steel layers of this example, incombination with preferred silver and copper layer thicknesses,duplicate a desired low reflectance pinkish colored appearance. Thefinal coated article has a luminous reflectance of about 37.5 percentand chromaticity coordinates of x=0.3408 and y=0.3363 with respect toIlluminant D-65. The improved stability of the silver/copper film withthe stainless steel overcoat is evaluated by means of a heat soak testwherein coated samples are placed in an oven at 275° F. (135° C.) for 5hours. Without the overcoat, untreated silver/copper films undergosignificant visible color changes. Silver/copper films treated with apassivating agent do not significantly change color, but becomenonuniform, e.g., streaked. However, when the silver/copper film isovercoated with stainless steel in accordance with the presentinvention, as in this example, there is no significant visible change inthe film, in either the color or the uniformity.

The above example is offered to illustrate the present invention.Various modifications, such as the use of other overcoat metals whichform a dense oxide at the surface, the sputtering of other sensitivemetals, and the coating of nonmetallic substrates other than glass,which need not be transparent, are included within the scope of thepresent invention as defined by the following claims.

We claim:
 1. An article of manufacture comprising:a. a transparentnonmetallic substrate; b. a transparent coating of a metal selected fromthe group consisting of silver, copper, gold, platinum, palladium andmixtures thereof; and c. a transparent protective overcoat comprising ametal having a dense oxide surface layer.
 2. An article of manufacturecomprising:a. a transparent nonmetallic substrate; b. a transparentprimer layer which bonds oxidatively to the substrate surface; c. atransparent coating of a metal selected from the group consisting ofsilver, copper, gold, platinum, palladium and mixtures thereof; and d. atransparent protective overcoat of a metal which forms a dense oxidesurface layer.
 3. An article according to claim 2, whereina. thesubstrate is glass; and b. the primer layer and overcoat are selectedfrom the group consisting of stainless steel, titanium, vanadium,chromium, aluminum, tin, tantalum and nickel alloys.
 4. An articleaccording to claim 3, wherein the primer layer and overcoat arestainless steel, and the coating is selected from the group consistingof silver, copper and mixtures thereof.
 5. An article according to claim4, wherein the coating comprises a first layer of silver and a secondlayer of copper.
 6. An article according to claim 5, wherein thestainless steel, silver and copper layers are of relative thicknesseswhich produce a low reflectance, pinkish colored article.